Disposable gloves and glove material compositions

ABSTRACT

The present invention generally relates to disposable gloves, ethylene-based thermoplastic materials for use in preparing disposable gloves, and methods for preparing ethylene-based thermoplastic materials for use in preparing disposable gloves. In particular, the present invention relates to non-medical and non-surgical disposable gloves suitable for use in food-service and industrial applications.

REFERENCE TO RELATED APPLICATION

This application is a continuation application of U.S. Ser. No.13/233,778, filed Sep. 15, 2011, the entire contents of which are herebyincorporated by reference for all relevant purposes.

FIELD OF THE INVENTION

The present invention generally relates to disposable gloves,ethylene-based thermoplastic materials for use in preparing disposablegloves, and methods for preparing ethylene-based thermoplastic materialsfor use in preparing disposable gloves. In particular, the presentinvention relates to non-medical and non-surgical disposable glovessuitable for use in food-service and industrial applications.

BACKGROUND OF THE INVENTION

Disposable plastic gloves are manufactured according to high qualitystandards to protect hands and fingers from exposure to bacteria,viruses, and other contaminants commonly found in medical and hospitalsettings, food preparation areas, biologic engineering laboratories,electromechanical and manufacturing work, inspection industries,automotive repair, household, and so on. Gloves are also used to protectagainst contamination of, for example, pharmaceuticals and foods thatmay be handled.

Disposable plastic gloves are manufactured with several considerationsin mind, such as:

1. materials costs,

2. environmental impact,

3. durability,

4. comfort,

5. sanitation,

6. ability to form a protective barrier, and

7. use of hypo- or non-allergenic materials.

Disposable gloves are conventionally manufactured from a mixture ofpolymers, typically a low density polyethylene and high densitypolyethylene, because of the low cost of the materials, the inertness ofthe materials to a wide range of chemicals, and the flexibility of thegloves over a wide range of temperatures. However, the materials used inthe manufacture of disposable polyethylene gloves may result in glovesthat may not meet certain above-mentioned requirements. For example,gloves manufactured from a mixture of a low density polyethylene andhigh density polyethylene may not be comfortable and may tear easily.

Disposable gloves may also be manufactured from different materials,such as vinyl, natural rubber latex, or synthetic latex. While eachmaterial provides certain advantages that render gloves made therefromuseful, each material also suffers certain disadvantages, as set forthin the following table.

Plastics Pro Con Polyethylene Hypo-allergenic Easy tear Excellentchemical Leakage at heat sealed resistance seams Economical Not ascomfortable as Low environmental impact Latex Capable protective Poordexterity barrier Vinyl Economical Allergic reaction Good dexterity Poorbarrier capability Comfortable Not as comfortable as latex Environmentalimpact Natural Capable protective Allergic reaction Rubber Latex barrierChemical resistance Comfortable Environmental impact Excellent dexteritySynthetic Excellent Barrier Allergic reaction Latex capabilityEnvironmental impact Durable Not as comfortable as Excellent dexteritylatex High cost

Suitable gloves have been manufactured from the above-mentionedmaterials, including disposable gloves constructed from a mixture of ahigh density polyethylene and a low density polyethylene. Other suitablegloves may be constructed of mixtures of ethylene-based polymersincluding a first ethylene-based metallocene-linear low densitypolyethylene (m-LLDPE) and at least one ethylene-based polymer selectedfrom a second metallocene-linear low density polyethylene (m-LLDPE), anethylene-vinyl acetate copolymer (EVA), and a linear low densitypolyethylene (LLDPE). While these gloves have proven effective for theirvarious applications including, for example, as disposable food-servicegloves, there remains the opportunity for further improvements thatovercome one or more of the above-noted disadvantages including, forexample, improvements in donning and gripping ability of the gloves andthe strength characteristics of the gloves.

SUMMARY OF THE INVENTION

The present invention is generally related to disposable glovesconstructed of a glove construction material including a plurality ofethylene-based polymer layers. The glove construction material isgenerally constructed of a plurality of films, each film including aplurality of ethylene-based polymer layers. The ethylene-based polymerlayers are generally constructed of (I) a first metallocene-linear lowdensity polyethylene (M-LLDPE), and (II) at least one ethylene-basedpolymer selected from the group consisting of a secondmetallocene-linear low density polyethylene (m-LLDPE), an ethylene-vinylacetate copolymer (EVA), a linear low density polyethylene (LLDPE), andcombinations thereof. The disposable gloves of the present invention aregenerally non-medical, non-surgical gloves and particularly suited forfood-service and industrial applications.

One aspect of the present invention involves incorporating one or moresurface modification agents into one or more of the ethylene-basedpolymer layers to provide improved donning ability of the wearer of theglove and also improved gripping ability.

Another aspect of the present invention generally involves incorporatinga coloring agent into one or more of the ethylene-based polymer layersto indicate, for example, the size of the glove, the right- orleft-handedness of the glove, and/or the presence of one or moreadditives (e.g., an antibacterial agent).

Briefly, therefore, the present invention is directed to a disposableglove comprising a glove construction material adapted for receiving athumb, fingers, and/or a hand therein, and comprising a plurality ofethylene-based polymer layers. The glove construction material comprises(a) a first film and (b) a second film. The first film comprises (i) afirst inner layer comprising (I) a first metallocene-linear low densitypolyethylene (m-LLDPE), and (II) at least one ethylene-based polymerselected from the group consisting of a second metallocene-linear lowdensity polyethylene (m-LLDPE), an ethylene-vinyl acetate copolymer(EVA), a linear low density polyethylene (LLDPE), and combinationsthereof, and (ii) a first outer layer comprising (I) a firstmetallocene-linear low density polyethylene (m-LLDPE), and (II) at leastone ethylene-based polymer selected from the group consisting of asecond metallocene-linear low density polyethylene (m-LLDPE), anethylene-vinyl acetate copolymer (EVA), a linear low densitypolyethylene (LLDPE), and combinations thereof. The second filmcomprises (iii) a second inner layer comprising (I) a firstmetallocene-linear low density polyethylene (m-LLDPE), and (II) at leastone ethylene-based polymer selected from the group consisting of asecond metallocene-linear low density polyethylene (m-LLDPE), anethylene-vinyl acetate copolymer (EVA), a linear low densitypolyethylene (LLDPE), and combinations thereof, and (iv) a second outerlayer comprising (I) a first metallocene-linear low density polyethylene(m-LLDPE), and (II) at least one ethylene-based polymer selected fromthe group consisting of a second metallocene-linear low densitypolyethylene (m-LLDPE), an ethylene-vinyl acetate copolymer (EVA), alinear low density polyethylene (LLDPE), and combinations thereof.

In accordance with various such embodiments, the first inner layerfurther comprises one or more surface modification agents in aproportion of between 5% and 20%, the first outer layer furthercomprises one or more surface modification agents in a proportion ofbetween 1% and 10%, the second inner layer further comprises one or moresurface modification agents in a proportion of between 5% and 20%, andthe second outer layer further comprises one or more surfacemodification agents in a proportion of between 1% and 10%.

In still further such embodiments, the first inner layer furthercomprises one or more surface modification agents; the first outer layerfurther comprises one or more surface modification agents, wherein theratio of the total proportion of the one or more surface modificationagents in the first inner layer to the total proportion of surfacemodification agents in the first outer layer is at least 2:1 (wt. %/wt.%); the second inner layer further comprises one or more surfacemodification agents; and the second outer layer further comprises one ormore surface modification agents, wherein the ratio of the totalproportion of surface modification agents in the second outer layer tothe total proportion of surface modification agents in the second innerlayer is at least 2:1 (wt. %/wt. %).

In still further such embodiments, the first inner layer furthercomprises one or more surface modification agents; the first outer layerfurther comprises one or more surface modification agents, wherein theratio of the coefficient of friction (COF) of the exposed surface of thefirst outer layer to the COF of the exposed surface of the first innerlayer is at least 1.5; the second inner layer further comprises one ormore surface modification agents; and the second outer layer furthercomprises one or more surface modification agents, wherein the ratio ofthe coefficient of friction (COF) of the exposed surface of the secondouter layer to the COF of the exposed surface of the second inner layeris at least 1.5.

In even further embodiments, the first inner layer further comprises oneor more surface modification agents; the first outer layer furthercomprises one or more surface modification agents; the second innerlayer further comprises one or more surface modification agents; and thesecond outer layer further comprises one or more surface modificationagents, wherein the exposed surfaces of the first inner layer and thesecond inner layer have a coefficient of friction (COF) of less thanabout 0.3 and the exposed surfaces of the first outer layer and thesecond outer layer have a COF of at least about 0.5.

The present invention is further directed to a disposable glovecomprising a glove construction material adapted for receiving a thumb,fingers, and/or a hand therein, and comprising a first film and a secondfilm. Each film comprises (i) an inner layer comprising (I) a firstmetallocene-linear low density polyethylene (m-LLDPE), and (II) at leastone ethylene-based polymer selected from the group consisting of asecond metallocene-linear low density polyethylene (m-LLDPE), anethylene-vinyl acetate copolymer (EVA), a linear low densitypolyethylene (LLDPE), and combinations thereof, and (ii) an outer layercomprising (I) a first metallocene-linear low density polyethylene(m-LLDPE), and (II) at least one ethylene-based polymer selected fromthe group consisting of a second metallocene-linear low densitypolyethylene (m-LLDPE), an ethylene-vinyl acetate copolymer (EVA), alinear low density polyethylene (LLDPE), and combinations thereof.

In various such embodiments, the glove construction material has athickness of at least 50 μm and a density of less than 0.92 g/cm³.

In accordance with further such embodiments, the glove is apolyurethane-free disposable glove and the glove construction materialis characterized by a tensile strength at yield (MD) and a tensilestrength at yield (TD) of less than 40 MPa, and a tensile elongation atbreak (MD) and a tensile elongation at break (TD) of at least 500%.

In further such embodiments, the glove construction material hasthickness of from about 40 μm to about 60 μm and is characterized by:(i) a tensile strength at yield (MD) of no more than about 23 MPa;and/or (ii) a tensile strength at yield (TD) of no more than about 10MPa; and/or (iii) a tensile strength at break (MD) of no more than about40 MPa; and/or (iv) a tensile strength at break (TD) of no more thanabout 25 MPa; and/or (v) a tensile elongation at break (MD) of at leastabout 700%; and/or (vi) a tensile elongation at break (TD) of at leastabout 800%; and/or (vii) a tear strength (MD) of at least about 1 g/μm;(viii) a tear strength (TD) of at least about 2 g/μm; and/or (ix) dartimpact test results conducted in accordance with ASTM D1709 of at least10 grams/μm; and/or (x) the coefficient of friction of the exposedsurface of the inner layer of the first film and the exposed surface ofthe inner layer of second film being from about 0.1 to about 0.3; (xi)the coefficient of friction of the exposed outer surface of the outerlayer of the first film and the exposed surface of the outer layer ofthe second film being from about 0.1 to about 0.5.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a disposable glove of the present invention.

FIG. 2 depicts a cross-sectional view of glove construction material ofthe present invention in the form of a multilayer film including innerand outer layers.

FIG. 3 depicts a cross-sectional view of glove constructions material ofthe present invention in the form a multilayer film including inner,middle, and outer layers.

FIG. 4 depicts a glove of the present invention incorporating a coloringagent.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Described herein are disposable gloves constructed of a gloveconstruction material including a plurality of ethylene-based polymerlayers. Generally, the present invention is directed to disposablegloves constructed of thermoplastic material, which contains a donninglayer at the internal surface. For example, in one embodiment, the glovecontains a thermoplastic material body in which a donning layer thatcontains a blend of two or more ethylene-based polymers and surfacemodification agents. It has been discovered that the application of ablend of two or more polyethylenes and surface modification agents tothe internal surface of the glove may provide both damp and dry donningability to the resulting thermoplastic glove.

Wearers of prior disposable gloves constructed of ethylene-basedpolymers and other materials often have difficulty in donning the glovesand also gripping objects. Gloves with insufficient grip properties maycause workers to grasp harder and exert more force when dealing withobjects in the workplace, particularly oily or slippery objects.Workplace efficiency may become compromised as workers will becomefrustrated and more prone to mistakes and accidents. Glove coatings suchas sponge nitrile rubber reduce this problem by absorbing much of theoil on the surface of the glove. However, the cost and other effectsfrom this additional treatment may be increased and more risky. Variousgloves of the present invention preferably contain one tacky surface.The tacky surface is preferably on the external portion, or surface ofthe glove that comes into contact with the object to be grasped by thewearer and provides hand stability and appropriate grip propertiesduring use. Tacky regions have numerous utilities, but principallyfunction to provide finger holds or areas of demarcation in the mittwithout having to define finger or thumb areas or otherwise provideborder areas that would increase processing expense. The tacky areasalso allow for places to grip or securely position the mitt or glove onthe user's hand. The tacky exterior surface of the gloves of the presentinvention is provided by incorporating one or more surface modificationagents as detailed elsewhere herein into the outer ethylene-basedpolymer layers of the glove construction material to provide a tackyexterior surface of the glove that comes in contact with the object tobe grasped by the wearer. Along with tacky exterior surfaces, gloves ofthe present invention include smooth interior surfaces that come incontact with the wearer's hand during donning of the glove and thusprovide ease in donning of the glove. The ease in donning of the gloveis provided by incorporating one or more surface modification agentsinto the inner ethylene-based polymer layers that come in contact withthe wearer's hand during donning.

In addition to easier donning and improved tackiness for graspingobjects, gloves of the present invention provide improved strengthcharacteristics as compared to other ethylene-based disposable glovesincluding, for example, ethylene-based gloves constructed ofhigh-density polyethylene (HDPE). Although HDPE-based gloves have proveneffective in various applications, including food-service applications,improvements in certain strength characteristics of these gloves wouldbe desired. Gloves of the present invention constructed of layersincluding mixtures of m-LLDPE polymers provide improved strengthcharacteristics over conventional HDPE-based gloves. One aspect of thepresent invention that provides this improved strength is theutilization of multiple films, each film constructed of a plurality ofethylene-based polymer layers.

A further advantage of the disposable gloves of the present invention isthat the ethylene-based polymers allow for preparation of gloves of atleast comparable strength and performance characteristics at a reducedcost as compared to similar performing gloves that are constructed ofmore costly materials. For example, vinyl-based (e.g., polyvinylchloride(PVC)-based) gloves have proven to exhibit suitable strengthcharacteristics, but the cost of vinyl-based materials has increased inrecent years, while the cost of ethylene-based polymers has decreased.Accordingly, as of the time of applicants' invention, ethylenepolymer-based gloves can be prepared at a reduced cost as compared tosimilar performing vinyl-based gloves. The ethylene-based polymer glovesof the present invention also provide one or more advantageous featuresas compared to disposable gloves constructed of other conventional gloveconstruction materials. For example, latex disposable gloves generallyexhibit one or more desirable characteristics (e.g., barrier protection,strength/durability, elasticity, and fit/comfort) and can be prepared atrelatively low cost. Ethylene-based gloves of the present inventionexhibit these advantageous features, but also typically exhibit superiorpuncture resistance as compared to latex-based gloves while alsoavoiding user allergy issues that can be seen with latex-based gloves.With respect to nitrile-based gloves (e.g., acrylonitrile andbutadiene), ethylene-based polymer gloves of the present invention atleast equal the nitrile-based gloves with regard to performancecharacteristics (e.g., barrier protection and strength/durability) whilealso providing advantages over nitrile-based gloves in terms of otherfeatures (e.g., elasticity and fit/comfort), while also being preparedat lower cost than nitrile-based gloves. The ethylene-based polymergloves of the present invention also exhibit at least comparableperformance characteristics as compared to polyurethane-based gloves,while being prepared at lower cost. Accordingly, the gloves of thepresent invention provide many advantages over conventional glovesgenerally and, more particularly, provide many advantages by virtue ofat least matching and often exceeding performance characteristics ofconventional disposable gloves, while being prepared at lower cost.

Further in accordance with the present invention, the films comprisingthe ethylene-based polymer layers are constructed of a plurality ofethylene-based polymer layers. In various embodiments, the films includeinner and outer ethylene-based polymer layers and, in various otherembodiments, further include middle layers disposed between the innerand outer layers. It has been discovered that this multilayerarrangement provides films that exhibit improved strengthcharacteristics as compared to films of similar thicknesses constructedof, for example, high-density ethylene-based polymers and vinyl polymersand, thus, allow for preparation of glove construction materials andgloves of improved strength characteristics without requiring thickergloves. This represents an advance in the art since thinner gloves aregenerally preferred for purposes of wearer comfort, dexterity, and alsoeconomics since as thickness of the gloves and films increases the costassociated with film and glove manufacture likewise increases.

As used herein, the term “disposable” is used in its ordinary sense tomean an article that is disposed of or discarded after a limited numberof usage events, preferably less than 10, more preferably less thanabout 5, and most preferably less than about 2 entire usage events. Asused herein, the term “glove” refers to a covering adapted for awearer's hand, thumb, and/or one or more fingers of a wearer. In variousembodiments, “glove” refers to a covering for a wearer's hand, thumb,and each finger. In various other embodiments, “glove” refers to acovering for a portion of a wearer's hand and the wearer's fingers, or acovering for only one or more of the wearer's fingers and/or thumb. Suchcoverings that do not cover the entire hand and each finger and thumb ofthe wearer are often referred to in the art as “finger sacks.” It is tobe understood that reference to “glove” herein thus refers to a coveringfor any or all of a portion of a wearer's hand, including the wearer'sthumb and/or one or more fingers, and including “finger sacks.”

I. Multi-Layer Gloves

Generally, the present invention is directed to disposable glovesconstructed of a thermoplastic material comprising a blend of two ormore ethylene-based polymers and one or more surface modificationagents. The thermoplastic materials are typically constructed or formedinto a thin film. Films manufactured from the thermoplastic material ofthe present invention are characterized by significantly improvedtoughness, tear strength, and heat seal strength compared toconventional polyolefin films known in the art. The thermoplasticmaterials may be constructed through different extrusion processes suchas casting or blowing mold into a thin thermoplastic film of which thestructure of the film comprises two or more layers. The one or moresurface modification agents are incorporated into the layers of thefilms in varying proportions, thereby providing films characterized bysignificant differences in surface texture for both sides of the film.

Various embodiments of the present invention are directed to disposablegloves constructed of more than one film prepared from a thermoplasticmaterial comprising ethylene-based polymers. FIG. 1 generally depicts aglove 1 of the present invention constructed of a first film 3 and asecond film 5. As a general matter, the thermoplastic material used toprepare the films comprises a high performance, conventional orsingle-site metallocene-linear low density polyethylene (m-LLDPE) andone or more additional ethylene-based polymers selected from a secondmetallocene-linear low density polyethylene (m-LLDPE), an ethylene-vinylacetate copolymer (EVA), a linear low density polyethylene (LLDPE), orany combination thereof, plus optional additives such as surfacemodification agents.

Generally, the films include an inner, or internal layer that contactsthe wearer's hand and an outer, or external layer that contacts theitem(s) grasped by the wearer. FIG. 2 provides a cross-sectional view offirst film 3 and second film 5 of the glove of FIG. 1. As shown in FIG.2, the first film 3 and second film 5 include inner layers 50 and 60,respectively that will be in contact with the wearer's hand. First film3 and second film 5 also include outer layers 70 and 80, respectively,that will come in contact with the item to be grasped or handled. Theinternal layer can be formulated, e.g., having a slippery, or otherstructure to provide better hand feel. The feel of the inner layer canalso be controlled by adjusting the coefficient of friction of thelayer. The external layer can be formulated, e.g., having a sticky, orother structure to provide grip feel and improved gripping ability. Thefeel of the outer layer can also be controlled by adjusting thecoefficient of friction of the layer.

A. Inner and Outer Layers

Generally, the inner and outer layers are constructed of thermoplasticmaterial comprising a high performance, conventional or single-sitemetallocene-linear low density polyethylene (m-LLDPE) and one or moreadditional ethylene-based polymers selected from a secondmetallocene-linear low density polyethylene (m-LLDPE), an ethylene-vinylacetate copolymer (EVA), a linear low density polyethylene (LLDPE), orany combination thereof has the properties of a thermoplastic elastomer.A thermoplastic elastomer, in the context of the present invention,denotes a low modulus, highly flexible, and highly elastic materialcomprising two or more ethylene-based polymers in such intimate contactso as to form reversible, non-covalent cross-links such as by hydrogenbonding, dipole, or van der Waal's interactions. Intimate mixing of thetwo or more polymers may be accomplished by means known in the art, forexample, casting extrusion, and blow molding extrusion.

In some embodiments, the thermoplastic material of an inner or outerlayer comprises a metallocene-linear low density polyethylene (m-LLDPE)and an ethylene-vinyl acetate copolymer (EVA). In some embodiments, thethermoplastic material of an inner or outer layer comprises acombination of a metallocene-linear low density polyethylene (m-LLDPE)and a linear low density polyethylene (LLDPE). In some embodiments, thethermoplastic material of an inner or outer layer comprises acombination of a first metallocene-linear low density polyethylene(m-LLDPE) and a second metallocene-linear low density polyethylene(m-LLDPE). In some embodiments, the thermoplastic material comprises acombination of a first metallocene-linear low density polyethylene(m-LLDPE), a second metallocene-linear low density polyethylene(m-LLDPE), and an ethylene-vinyl acetate copolymer (EVA). In someembodiments, the thermoplastic material of an inner or outer layercomprises a combination of a first metallocene-linear low densitypolyethylene (m-LLDPE), a second metallocene-linear low densitypolyethylene (m-LLDPE), and a linear low density polyethylene (LLDPE).In some embodiments, the thermoplastic material of an inner or outerlayer comprises a combination of a metallocene-linear low densitypolyethylene (m-LLDPE), an ethylene-vinyl acetate copolymer (EVA), and alinear low density polyethylene (LLDPE). In some embodiments, thethermoplastic material of an inner or outer layer comprises acombination of a first metallocene-linear low density polyethylene(m-LLDPE), a second metallocene-linear low density polyethylene(m-LLDPE), an ethylene-vinyl acetate copolymer (EVA), and a linear lowdensity polyethylene (LLDPE).

It has been surprisingly found that the thermoplastic materialcomprising two or more ethylene-based polymers not only gives theexcellent heat seal strength and lower heat seal temperature but alsooffer the film with toughness, tear strength, and excellent dexteritywhich will offer better functionality than conventional disposablepolyolefin films.

In various embodiments, the thermoplastic material of an inner or outerlayer comprising two or more ethylene-based polymers comprises a highperformance, conventional or single-site metallocene-linear low densitypolyethylene (m-LLDPE). M-LLDPE is so-named due to the metallocenecatalyst that catalyzes the polymerization of ethylene. The m-LLDPE hasa density within the range of about 0.86 grams per cubic centimeter toabout 0.92 grams per cubic centimeter, such as between about 0.87 gramsper cubic centimeter to about 0.905 grams per cubic centimeter. Densitymay be measured by ASTM D792. The m-LLDPE has a melt index (MI) withinthe range of about 0.5 decigrams (dg)/min to about 5.0 dg/min, such asbetween about 1.0 dg/min to about 2.0 dg/min. The method for determiningthe melt index is described in the standards ASTM D1238 and ISO 1133.

M-LLDPE polymers provide excellent tear strength, toughness, andelasticity. Elasticity in the thermoplastics field is generallydetermined by a combination of tensile strength at yield and tensileelongation at break. In the context of the present invention, thethermoplastic material is characterized by low tensile strength at yieldand high tensile elongation at break. Yield point is the point on thestress-strain curve, where the slope of the curve becomes zero. Tensilestrength at yield reflects the stress at this point in the stress-straincurve. Tensile strength at yield may be measured at both the machinedirection (MD) orientation and the transverse direction (TD)orientation. Break point is the point at which the material ruptures.Tensile elongation at break is the percentage increase in length beforeit breaks under tension. Tensile elongation may be measured at both themachine direction (MD) orientation and the transverse direction (TD)orientation. Both quantities are measured according to the standard setforth in ASTM D882. Metallocene-LLDPE having densities near or belowabout 0.9 g/cm³ are preferred since they tend to provide excellentelastic recovery in terms of low tensile strength at yield and hightensile elongation at break. That is, it is preferred to prepare thethermoplastic material of the present invention with an elastomericm-LLDPE since the elastic recovery property is a distinct advantage ofthis component of the combination to the elasticity of the finalresultant thermoplastic elastomer. The properties provided by therelatively low density of the ethylene-based polymer gloves provideadvantages over gloves constructed of other conventional materialsincluding, for example, polyurethane-based gloves.

The thermoplastic material used to prepare an inner and/or outer layerand the resulting multi-layer films of the present invention preferablycomprises a relatively low density m-LLDPE having a tensile strength atyield (MD) that is no more than about 14 MPa (about 2000 psi), no morethan about 10 MPa (about 1450 psi), or even no more than about 8.5 MPa(about 1200 psi). Preferably, the tensile strength at yield (TD) is nomore than about 14 MPa (about 2000 psi), no more than about 10 MPa(about 1450 psi), or even no more than about 6.9 MPa (about 1000 psi).

Preferably, the tensile elongation (MD) at break is at least 400%, atleast 500%, or at least 600%. Preferably, the tensile elongation (TD) atbreak is at least 400%, at least 500%, or at least 600%.

Preferred m-LLDPE polymers exhibit excellent tear strength, as measuredby the Elmendorf test method ASTM D 1922 (2 mil/50 micrometer sample) inboth the machine direction (MD) orientation and the transverse direction(TD) orientation. Preferably, the tear strength (MD) is at least 350grams, at least about 450 grams, or even at least about 500 grams.Preferably, the tear strength (TD) is at least about 500 grams, at leastabout 600 grams, or even at least at least about 700 grams.

Toughness may be measured by the Dart Impact, ASTM D1709 standard (2-4mils/50-100 microns sample). Falling dart impact is a traditional methodfor evaluating the impact strength or toughness of a plastic film. Thistest uses a single dart configuration and a single drop height, whilevarying the weight of the dart. Preferably, the toughness of the m-LLDPEas measured by the falling dart impact is at least about 700 grams, oreven at least about 800 grams.

The thermoplastic material comprising two or more ethylene-basedpolymers generally comprises between about 30 wt. % and about 75 wt. %of the m-LLPDE component, such as between about 35 wt. % and about 65wt. %, or even between about 45 wt. % and about 65 wt. %. In someembodiments, the thermoplastic material generally comprises betweenabout 30 wt. % and about 50 wt. % m-LLDPE polymer.

M-LLDPE polymers are available commercially, such as Versify™ 3401Elastomer and Plastomer polymers available from Dow Chemical, AFFINITYPL series, e.g., 1880G and 1881G, from The Dow Chemical Company too.

In some embodiments, the thermoplastic material of the inner and/orouter layers of the films of the present invention comprises a copolymercomprising ethylene and vinyl acetate (VA) repeat units. In general, theweight percent of the vinyl acetate repeat units in the ethylene-vinylacetate (EVA) copolymer weight percent may range from about 5 wt. % toabout 40 wt. %, preferably between about 9 wt. % and about 20 wt. %, thebalance being ethylene. In some embodiments, the VA content may behigher, such as between about 25 wt. % and about 40 wt. %, such asbetween about 30 wt. % and about 35 wt. %. In general, the EVA copolymerhas a density from about 0.920 grams per cubic centimeter to about 0.950grams per cubic centimeter, such as from about 0.930 grams per cubiccentimeter to about 0.940 grams per cubic centimeter. Density may bemeasured by ASTM D1505. The EVA copolymer has a melt index (MI) fromabout 1.0 dg/min to about 5.0 dg/min. The melt index may be measured byASTM D1238.

EVA copolymers provide excellent processability, low temperaturesealing, and chemical resistance. Advantageously, EVA copolymers arevery elastic, as measured by tensile strength at yield and tensileelongation at break, both under the ASTM D638 standard. The EVAcopolymer may have a tensile strength at yield (ASTM D638) of less thanabout 80 kg/cm² (about 8 MPa), less than about 70 kg/cm² (about 7 MPa),or even less than 50 kg/cm² (about 5 MPa). Preferably, the EVA polymeris characterized by tensile elongation at break (ASTM D638), which maybe at least 600%, at least 700%, or even at least 800%. The EVAco-polymer is therefore an advantageous component of the thermoplasticmaterial due to its excellent elastomeric properties, as measured by lowtensile strength at yield and high elongation at break. Therefore, it ispreferred to prepare the thermoplastic material of the present inventionwith an elastomeric EVA copolymer since the elastic recovery property isa distinct advantage of this component to the elasticity of the finalresultant thermoplastic elastomer.

In certain embodiments, the thermoplastic material of these embodimentsgenerally comprises between about 30 wt. % and about 70 wt. % EVAcopolymer, more preferably between about 30 wt. % and about 50 wt. % EVAcopolymer.

EVA copolymers are available commercially, such as TAISOX® EVAcopolymers, available from Formosa Plastics Corporation, ELVAX® EVAcopolymers, available from DuPont, and Tritheva® EVA copolymers,available from Petroquimica Triunfo.

In these and other embodiments, the thermoplastic material of the innerand/or outer layers of the films of the present invention comprises alinear low density polyethylene (LLDPE). Linear low-density polyethylene(LLDPE) is a substantially linear polymer (polyethylene), withsignificant numbers of short branches, commonly made by copolymerizationof ethylene with longer-chain olefins, such as butene, hexene, oroctene. Preferred LLDPE polymer comprise ethylene-based polymercopolymerized with butene. The LLDPE has a density within the range ofabout 0.83 grams per cubic centimeter to about 0.925 grams per cubiccentimeter, such as between about 0.85 grams per cubic centimeter toabout 0.90 grams per cubic centimeter. Density may be measured by ASTMD1505. The LLDPE has an MI within the range of about 0.25 dg/min toabout 2.0 dg/min, such as between about 0.45 dg/min to about 1.0 dg/min.The melt index may be measured by ASTM D1238.

LLDPE polymers are chosen to enhance the toughness, tear strength, andstretchability of the thermoplastic material. LLDPE polymers arecharacterized by tensile elongation (MD) at break is at least 300%, atleast 400%, or at least 500%. Preferably, the tensile elongation (TD) atbreak is at least 500%, at least 600%, or at least 700%. LLDPE polymersare additionally an economical additive. In some embodiments, thethermoplastic material generally comprises between about 30 wt. % andabout 50 wt. % LLDPE polymer and in other embodiments between about 10wt. % and about 30 wt. % LLDPE polymer.

LLDPE polymers are available commercially, such as the Formolene L42099polymers available from Formosa Plastics.

The films resulting from the combination of ethylene-based polymerlayers generally have a thickness of at least about 5 μm and typicallyfrom about 5 to about 40 μm or from about 20 to about 30 μm.

B. Surface Modification Agents

As noted, various embodiments of the invention are directed todisposable gloves that include a relatively smooth surface of an inner,donning layer and a relatively tacky surface of an exterior, graspinglayer. These properties are provided by incorporating one or moresurface modification agents into the inner and outer layers of themultilayer films used to prepare the disposable gloves. Suitable surfacemodification agents for this purpose include slip additives andanti-block additives. In this manner, the inner and outer layers of thefilms used to construct the disposable gloves are modified by virtue ofthe presence of one or more components (i.e., are chemically modified).Other methods used to adjust the surface properties of thermoplasticmaterials include roughening of the surface of the material by, forexample, embossing the surfaces of the material during manufacture.Gloves of the present invention may include embossed inner and outersurfaces. However, adjustment of surface properties by selection of filmadditives as described herein as the at least primary and often onlymode of surface modification is preferred since modification byroughening or embossing of the glove construction material maynegatively impact glove strength. For example, when surfaces areroughened by embossing, the texture surface will often change when theglove is subjected to temperature conditions that are higher than theembossing temperature.

A slip additive is a plastics modifier that acts as a lubricant byexuding to the surface of the plastic during and immediately afterprocessing to reduce friction between layers of film. Lower frictionfacilitates handling of the film and other surfaces, e.g., rollers, towhich the film comes into contact. Slip additives are generally fattymaterials, such as, for example, long chain fatty acids, alcohols, andamides. Preferred slip additives are fatty amides having carbon chainsgenerally ranging from 14 to 22 carbon atoms, such as from 15 to 19carbon atoms. In various embodiments, the slip additive is selected fromthe group consisting of oleamide, stearic amide, and combinationsthereof.

An antiblock additive is a plastics modifier that is generally added toprevent blocking, which occurs when two adjacent layers of film adheretogether when pressed together, such as during windup on a roll or filmstacking. Antiblock additives are added to form micro-bumps on thesurface of a plastic film, which minimizes film to film contact.Antiblock additives may be inorganic materials, such as natural silicaparticles, talc, synthetic silica, calcium carbonate, ceramic spheres,kaolin/clay, and mica. Organic antiblock additives include ethylenebisstearamide, stearyl erucamide, stearamide, erucamide, glycerolmonostearate, zinc stearate, silicone, and PTFE.

Generally, the thermoplastic material of the present invention maycomprise between about 1 wt. % and about 10 wt. % of surfacemodification agents, such as between about 5 wt. % and about 10 wt. % ofsurface modification agents. Preferably, the thermoplastic materialcomprises both an anti-block additive and a slip additive as surfacemodification agents. Thus, generally the thermoplastic materialpreferably comprises between about 1 wt. % and about 10 wt. %, such asbetween about 5 wt. % and about 10 wt. % of an anti-block additive. Inaddition, the thermoplastic material preferably further comprisesbetween about 1 wt. % and about 10 wt. %, such as between about 5 wt. %and about 10 wt. % of a slip additive.

To impart the relatively smooth inner surface and relatively tacky outersurface, preferably the inner layers include a greater proportion ofsurface modification agent than the outer layers. For example, typicallythe ratio of the total proportion of surface modification agent(s) inthe inner layers to the total proportion of surface modificationagent(s) in the outer layers is at least about 1.5:1 (wt. %/wt. %),typically at least about 2:1 (wt. %/wt. %), and preferably at leastabout 2.5:1 (wt. %/wt. %).

Typically, the inner layer(s) include the surface modification agent(s)in a total proportion of from about 3 wt. % to about 20 wt. % (e.g.,from about 3 wt. % to about 10 wt. %) and, more typically, from about 5wt. % to about 20 wt. % (e.g., from about 5 wt. % to about 10 wt. %). Inaccordance with such embodiments, typically the inner layer(s) includean anti-block additive in a proportion of from about 1 wt. % to about 10wt. % (e.g., about 5 wt. %) or from about 5 wt. % to about 10 wt. %(e.g., about 7 wt. %). The inner layer(s) also typically include theslip additive in a proportion of from about 1 wt. % to about 10 wt. %(e.g., about 5 wt. %), or from about 5 wt. % to about 10 wt. % (e.g.,about 7 wt. %).

The outer layer(s) typically include the surface modification agent(s)in a total proportion of from about 1 wt. % to about 5 wt. %, or fromabout 1 wt. % to about 3 wt. %. In accordance with such embodiments,typically the outer layer(s) include an anti-block additive in a totalproportion of from about 1 wt. % to about 5 wt. % or from about 1 wt. %to about 3 wt. %. The outer layer(s) typically include the slip additivein a proportion of from about 1 wt. % to about 5 wt. %, or from about 1wt. % to about 3 wt. %.

Incorporating the surface modification agent(s) into the inner layer(s)and outer layer(s) and providing the relatively smooth inner, donningsurface of the glove and the relatively tacky exterior, grasping surfaceof the glove provide inner and outer surfaces of varying coefficients offriction (COF). Typically, the COF of the inner surface(s), or innerlayer(s) is less than about 0.3 or from about 0.1 to about 0.3 (e.g.,about 0.1). The COF of the outer surface(s) or outer layer(s) is atleast about 0.5 or from about 0.5 to about 1.0. These varyingcoefficients of friction can also be evidenced by the relative COFs ofthe inner and outer surfaces. For example, typically the ratio of theCOF of the outer surface to the inner surface is at least 1:1, moretypically at least about 1.5:1 (e.g., about 2:1).

C. Exemplary Embodiments

In one preferred embodiment, the thermoplastic material of the inner andouter layer(s) comprises between about 30 wt. % to about 70 wt. %m-LLDPE and between about 30 wt. % to about 70 wt. % of the EVAcopolymer. The thermoplastic material of the inner layer(s) may comprisebetween about 5 wt. % and about 10 wt. % of an anti-block additiveand/or may comprise between about 5 wt. % and about 10 wt. % of a slipadditive. Further in accordance with this embodiment, the thermoplasticmaterial of the outer layer(s) may comprise between about 1 wt. % andabout 5 wt. % of an anti-block additive and/or may comprise betweenabout 1 wt. % and about 5 wt. % of a slip additive.

In another preferred embodiment, the thermoplastic elastomer of theinner and outer layer(s) comprises about 40 wt. % m-LLDPE and about 40wt. % of the EVA copolymer, the balance being optional additives such asanti-block and slip additives. For example, the thermoplastic materialof the inner layer(s) comprises between about 5 wt. % and about 10 wt. %of an anti-block additive and/or between about 5 wt. % and about 10 wt.% of a slip additive. The thermoplastic material of the outer layer(s)comprises between about 1 wt. % and about 5 wt. % of an anti-blockadditive and/or between about 1 wt. % and about 5 wt. % of a slipadditive.

In another preferred embodiment the thermoplastic material of the innerand outer layer(s) comprises between about 35 wt. % and about 65 wt. %m-LLDPE, and between about 15 wt. % and about 45 wt. % LLDPE. Thethermoplastic material of the inner layer(s) may comprise between about5 wt. % and about 10 wt. % of an anti-block additive and/or betweenabout 5 wt. % and about 10 wt. % of a slip additive. Further inaccordance with this embodiment, the thermoplastic material of the outerlayer(s) may comprise between about 1 wt. % and about 5 wt. % of ananti-block additive and/or may comprise between about 1 wt. % and about5 wt. % of a slip additive.

In another preferred embodiment, the thermoplastic elastomer of theinner and outer layer(s) comprises between about 30 wt. % and about 55wt. % of a first m-LLDPE, and between about 30 wt. % and about 55 wt. %of a second m-LLDPE. The thermoplastic material of the inner layer(s)may comprise between about 5 wt. % and about 10 wt. % of an anti-blockadditive and/or between about 5 wt. % and about 10 wt. % of a slipadditive. Further in accordance with this embodiment, the thermoplasticmaterial of the outer layer(s) may comprise between about 1 wt. % andabout 5 wt. % of an anti-block additive and/or may comprise betweenabout 1 wt. % and about 5 wt. % of a slip additive.

In another preferred embodiment, the thermoplastic elastomer of theinner and outer layer(s) comprises between about 30 wt. % to about 50wt. % of the EVA copolymer, between about 10 wt. % and about 30 wt. %LLDPE, and between about 30 wt. % and about 50 wt. % m-LLDPE. Thethermoplastic material of the inner layer(s) may comprise between about5 wt. % and about 10 wt. % of an anti-block additive and/or betweenabout 5 wt. % and about 10 wt. % of a slip additive. Further inaccordance with this embodiment, the thermoplastic material of the outerlayer(s) may comprise between about 1 wt. % and about 5 wt. % of ananti-block additive and/or may comprise between about 1 wt. % and about5 wt. % of a slip additive.

D. Middle Layer

Further in accordance with the foregoing, in various preferredembodiments, the multilayer films of thermoplastic material furthercomprise a middle layer disposed between the inner and outer layer of amultilayer film used to form the disposable glove. FIG. 3 provides acut-away view of a portion of the glove depicted in FIG. 1 and provide across-sectional view of the first film 3 and second film 5. First film 3and second film 5 include inner layers 100 and 110, respectively, andalso include outer layers 140 and 150, respectively. Disposed betweenthe inner and outer layers, first film 3 and second film 5 includesmiddle layers 120 and 130, respectively. The middle layers providestrength characteristics to the multilayer films. They also impede, orprevent any substantial migration of the surface modification agentsbetween the inner and outer layers. In this manner, the middle layercontributes to maintaining the desired smooth inner surface and tackyexterior. Although preferred in various embodiments, it is to beunderstood that multilayer films that include only inner and outerlayers and do not include a separate and distinct middle layernonetheless provide films that provide disposable gloves having asuitably smooth inner surface and tacky exterior surface. Generally, amiddle layer may be incorporated into a thermoplastic film includinginner and outer layers of the properties discussed above including, inparticular, the above-noted Exemplary Embodiments. Advantageously, themiddle layer may be constructed of material discarded during glovemanufacture including, for example, material discarded after heatsealing and forming gloves from one or more multilayer films.

The middle layer is prepared from a thermoplastic material comprisingethylene-based polymers. Typically, the thermoplastic material of themiddle layer comprises a high performance, conventional or single-sitemetallocene-linear low density polyethylene (m-LLDPE). The middle layermay also comprise one or more additional ethylene-based polymersselected from a second metallocene-linear low density polyethylene(m-LLDPE), an ethylene-vinyl acetate copolymer (EVA), and/or a linearlow density polyethylene (LLDPE).

A middle layer may also include one or more additives including, forexample, fillers and/or other mineral additives.

The thickness of any middle layer is typically at least about 10 μm toprovide the desired effects noted above, but also typically no more thanabout 30 μm so as to not provide a film thicker than desired. Thus, thethickness of the middle layer is generally from about 10 μm to about 30μm and typically from about 15 μm to about 25 μm.

E. Additional Components

In addition to the above-described components, the thermoplasticmaterial utilized in the present invention may include additional andoptional components. It is not practical to presently envision anddescribe all potential independent additives such as perfumes, dyes,etc. The list is nearly endless considering the variety of potentialfunctionalities. For example, in addition to the above-noted surfacemodification agents other components can include, for example, UVinhibitors, colorants, and fillers, and others as are known in theplastic film industry.

In alternative embodiments, the material of the invention consistsessentially of the components and optional additives described herein inthat non-recited components that would materially affect the basic andnovel properties are excluded. And in further alternatives, the materialof the invention more strictly consists of the recited components andoptional additives.

Similarly, various embodiments of the present invention exclude thepresence of other materials commonly used to prepare disposable gloves.Certain embodiments of the present invention are directed to HDPE-freegloves, latex-free gloves, nitrile-free, vinyl-free, andpolyurethane-free gloves. For example, in some embodiments the contentof one or more of these is strictly limited to no more than 5 wt %(e.g., up to 5% HDPE, or up to 5% HDPE and 5% vinyl), or even no morethan 2 wt % or 1 wt %. Other embodiments are essentially oralternatively absolutely, HDPE-free, latex-free, nitrile-free,vinyl-free, and/or polyurethane-free. In fact, various embodiments ofthe present invention are directed to vinyl-free gloves that nonethelessexhibit the advantageous use and strength characteristics of vinylgloves, but prepared from lower-cost ethylene-based polymers. Forexample, the combination of the tensile strength properties (e.g., atensile strength at yield (MD) and/or tensile strength at yield (TD) ofno more than 14 MPa (about 2000 psi) and a tensile elongation at break(MD) and a tensile elongation at break (TD) of at least 500%) representan advance over gloves constructed of other conventional materialsincluding, for example, polyurethane-based gloves. Further in accordancewith the present invention, ethylene polymer-based, vinyl-free glovesexhibit various advantageous features as compared to vinyl-based gloves,including one or more of the following: (i) a tensile strength at yield(MD) of less than about 20 MPa; and/or (ii) a tensile strength at yield(TD) of less than about 20 MPa; and/or (iii) a tensile strength at break(MD) of less than about 40 MPa; (iv) a tensile strength at break (TD) ofless than about 30 MPa; (v) a tensile elongation at break (MD) of atleast about 700%; and/or (vi) a tensile elongation at break (TD) of atleast about 800%; and/or (vii) a tear strength (MD) of at least about 1g/μm; and/or (viii) a tear strength (TD) of at least about 2 g/μm;and/or (ix) dart impact test results conducted in accordance with ASTMD1709 of at least about 10 g/μm; and/or (x) COFs of the exposed surfacesof the first inner layer and second inner layer is from about 0.1 toabout 0.5; and/or (xi) COFs of the exposed surfaces of the first outerlayer and second outer layer is from about 0.1 to about 0.5.

II. Methods of Preparation

The present invention is further directed to methods for preparing thinfilms from the thermoplastic elastomer materials discussed above. Thefilm is then further processed into disposable gloves. The gloves may bemanufactured via processes such as casting into lightweight films (Castfilm) or being blown into lightweight films (blown films). In general,one sheet of film is folded and the resulting dual sheet is heat sealedto form the gloves. Alternatively, two sheets of film prepared from thethermoplastic elastomer of the present invention may be seamed and heatsealed to form gloves. Advantageously, by virtue of incorporation ofsurface modification agents that provide easier donning ability, themethods of the present invention allow for preparation of gloves thatare non-powdered (i.e., powder-free).

Given the economy of heat sealing compared to other methods of makinggloves, a preferred method of manufacture of disposable gloves is byheat sealing. In another aspect, therefore, the present invention isdirected to a method of manufacturing the film into an article, themethod comprising heat sealing two layers of film. In one preferredembodiment, two layers of film are heat sealed and die cut into amulti-layer article, for example, disposable plastic gloves.Accordingly, there is provided an improved article, e.g., plastic glove,comprising two films of thin thermoplastic material of the presentinvention bonded to one another along a seal line conforming generallyto the required finger and hand outline of the required glove. Ingeneral, the method of manufacture comprises folding a film double as itis drawn off the roll, with the line of the fold in the machinedirection, then passing the double layer of plastic into a reciprocatingheat seal and cut out die, where the glove seams are made and the gloveis cut out, all in one single, rapid motion.

In preparing the film comprising the thermoplastic elastomer, theprocess comprises a first step of combining all component polymers andoptional additives for a particular layer in a continuous gravimetricblender which has several compartments for individual components. Thecomponents at all compartments are continuously fed and mixed into theblender according to the desired percentage weight which is controlledby load cells. Blenders for this process are commercially available, forexample, from K-Tron Process Group or Foremost Machine.

The components are blended through the continuous gravimetric blenderwhich has several individual compartments depending on the formulationand process requirement. Through gravity conveying, the blender providesa precise homogenous blend of materials. Process controls are determinedat the time of blending and generally depend upon the mass of materialadded, the relative weight percent of each component, and the blender.

The blended compound of an individual layer is loaded into an extruderhopper. The blended material in the hopper is gravimetrically conveyedinto the feeding zone of the extruder.

The heart of the extrusion process is an extruder which consists of ascrew and a die head (spiral mandrel). The extruder is essentially amachine used to melt the plastic and deliver the melted plastic underpressure to a die. Typically, extrusion begins with granular material,gravity-fed via a hopper to a rotary screw. The screw is a raisedflighted helix that traps material and moves it forward through anenclosed, heated barrel where it is first melted, and then pressurized.The extruder accomplishes solids conveying, melting or plasticating,mixing, melt conveying, degassing, and shaping or forming by, forexample, an extruder die.

The blended thermoplastic material is then extruded through a casting orblown die to convert the molten plastics into a thin film, the thin filmhaving a thickness of at least about 12.5 micrometers (at least about0.5 mil) and a surface area of at least about 25 cm², althoughtypically, the surface area of the film is much larger, i.e., on theorder of hundreds or even thousands of cm². The optimum set of operatingconditions can be determined through experience with a particularextruder. Optimum running conditions require the proper balancing ofmany variables such as:

-   -   Screw design including pump ratio, compressional ratio, Flight        depth, Flight height, etc.    -   Extruder size: L/D    -   Extrusion rate    -   Extruder conditions (temperatures, pressures, clearances,        surface roughness, etc.)    -   Formulation

The present method includes a multiple-layer extrusion method ofmanufacturing a thermoplastic material comprising two or moreethylene-based polymers and/or high density polyethylene, and surfacemodifier agents. The process includes extruding two or more materialsthrough a single die with two or more orifices arranged so that theextrudates merge and weld together into a laminar structure beforechilling. Each material is fed to the die from a separate extruder, butthe orifices may be arranged so that each extruder supplies two or moreplies of the same material. For example, in the case of a film includingan inner layer, middle layer, and outer layer, three extruders areutilized, one for each layer. Coextrusion can be employed in filmblowing, free film extrusion, and extrusion coating processes. Theadvantage of coextrusion is that each ply of the laminate imparts adesired characteristic property, such as stiffness, heat-sealability,impermeability or resistance to some environment, all of whichproperties would be impossible to attain with any single material.

The enhanced structural and physical properties of each layer materialcan be taken advantage of by dividing each individual layer into two ormore separate layers. A multilayer film is stronger than a monolayerfilm of the same thickness. Correspondingly, a co-extruded film hashigher melt strength and can be produced at a higher output rate withbetter stability. Advantageously, the multilayer films of the presentinvention exhibit higher melt strengths than other, for example,HDPE-based films. These higher melt strengths aid in processability.Incorporating more layers with dedicated extruders gives moreflexibility and saves money. For instance, an elastomeric skin layer canbe split into two layers by substituting a less expensive commodityresin for a high-cost elastomeric resin in the bulk of the skin andstill achieve the excellent sealing properties of the elastomer. Byadding more layers to the structure in this way, the film is madestronger, more economical and flexible.

The film thickness is controlled by the speed of a take-off or nip roll.The take-off speed may be adjusted to fine-tune the sheet thickness. Thefinished film gauge is typically at least about 12 micrometers (at leastabout 0.5 mil), and generally vary from about 20 micrometers and about200 micrometers (between about 0.8 mil and about 8 mil), such as fromabout 25 micrometers and about 50 micrometers (between about 1 mil andabout 2 mil). The density of the thermoplastic material is generallyless than about 0.925 g/cm³ and in some embodiments may be less thanabout 0.91 g/cm³, or even less than about 0.90 g/cm³. The film graduallycools down through a series of leading rolls which may have temperaturecontrol to reduce the film temperature to the ambient temperature beforewinding. The film may be rolled into a master roll prior to the articlemanufacture process (e.g., fold, cut, and seal process for manufacturingdisposable gloves).

For casting the film into an article, the extruded thin film is thenfolded double as it is drawn off the roll, with the line of the fold inthe machine direction. The double layers of plastic are then passed intoa reciprocating heat seal and cut out die, where the seams of thearticle are defined to thereby define an article, e.g., a glove, havinga surface area of at least about 25 cm². The article is heat sealed andcut out, all in one single, rapid motion. For blown film, the filmbubble can be directly heat sealed and die cut off without the foldingprocess.

Heat sealing is the thermal fusion of two (or more) melt-bond compatiblethermoplastic materials. All heat seals require the precise control ofheat, dwell time, and pressure to create a quality weld. These processcontrols are determined at the time of sealing. In general, the sealinitial temperature for preparing an article, e.g., a disposable glove,is generally less than 100° C., such as between about 80° C. and 90° C.,which compares favorably to the seal initial temperatures ofconventional polyolefin films employing high density polyethylene, whichare generally above 125° C. Thermal Impulse heat sealing is the processof welding thermoplastic films together by means of a resistanceribbon(s) through a cycle of heating and cooling under pressure. Bycontrolling the rate of heating and cooling, superior welds are createdwithout sacrificing the physical property values of the original film.Thermal impulse techniques are used to make bags, lay flat tubing,medical packaging, large panels, and protective garments.

The thermoplastic material of the present invention combines theprominent advantages of latex, nitrile, high density polyethylene(HDPE), and vinyl. The thermoplastic materials of the present inventionare further advantageous since they are easier to prepare than materialsmade from latex, nitrile, HDPE, and vinyl. For example, compared toprocesses for preparing articles such as disposable gloves from HDPE,the process for preparing articles using the thermoplastic material ofthe present invention have shorter cycle time and lower sealtemperature. Articles manufactured from latex, vinyl, and nitrile aremanufactured by the dipping mold process, which is substantially slowerthan the heat-seal-die cut method for preparing articles from thethermoplastic material of the present invention.

III. Glove Characteristics

As can be seen by the below examples, the thermoplastic material of thepresent invention, which are manufactured from two or moreethylene-based polymers, yield articles having mechanical propertiessuch as dexterity and tear strength that are much better thanpolyethylene articles currently on the market. Gloves of the presentinvention also exhibit strength characteristics at least comparable toother types of disposable gloves, including vinyl-based gloves whileovercoming disadvantages of these gloves (e.g., high material costs).For example, disposable gloves manufactured from films prepared fromthermoplastic elastomer of the present invention are particularlyelastic, having tensile strength at yield (MD) of no more than about 10MPa (about 1450 psi), tensile strength at yield (TD) of no more thanabout 10 MPa (about 1450 psi), tensile elongation at break (MD) of atleast about 500%, and tensile elongation at break (TD) of at least about700%.

Preferably, the tensile strength at yield (MD) is no more than about 14MPa (about 2000 psi), no more than about 10 MPa (about 1450 psi), oreven no more than about 6.9 MPa (about 1000 psi), such as between about4.2 MPa (about 600 psi) and 14 MPa (about 2000 psi). Preferably, thetensile strength at yield (TD) is no more than about 14 MPa (about 2000psi), no more than about 10 MPa (about 1450 psi), or even no more thanabout 6.9 MPa (about 1000 psi), such as between about 4.2 MPa (about 610psi) and 14 MPa (about 2000 psi). The tensile strength at yield may bemeasured by ASTM D882.

The tensile elongation at break (MD) may be at least about 500%, atleast about 600%, at least about 700%, or even at least about 800%. Thetensile elongation at break (TD) may be at least about 700%, at leastabout 800%, at least about 900%, or even at least about 1000%. Tensileelongation at break is measured by ASTM D882.

Incorporation of surface modification agents modify the film surfacestructure or roughness and, thus, the resulting surface structure ofroughness prepared from such films as measured by the coefficient offriction (COF) of glove surfaces. COF is a measure of the relativedifficulty with which one surface will slide over an adjoining surface.The greater the resistance to sliding the higher the COF value TheC.O.F. may be measured by ASTM D1894-78.

In various embodiments, the thermoplastic material of the internalsurface of gloves of the present invention has a coefficient of frictionof less than about 0.3 and a coefficient of friction of the externalsurface of the gloves of the present invention of at least about 0.5.The C.O.F. may be measured by ASTM D1894-78.

The thermoplastic material of the present invention is furthercharacterized by better tear strength than conventional polyolefinfilms. In this regard, the tear strength (MD) is generally at leastabout 1.6 g/micrometer (about 40 g/mil), at least about 2.0 g/micrometer(about 50 g/mil), at least about 2.4 g/micrometer (about 60 g/mil), oreven at least about 2.8 g/micrometer (about 70 g/mil), according to ASTMD1922. In some embodiments, the tear strength (MD) is between about 2.0g/micrometer (about 50 g/mil) and about 3.1 g/micrometer (about 80g/mil).

Additionally, since they are made from polyethylene materials, thethermoplastic elastomers are non-allergenic, environmentally-friendly,and more economical than articles manufactured from latex, vinyl, andnitrile.

Glove construction material, and gloves, of the present inventiontypically have a thickness of from about 15 to about 75 μm, or fromabout 40 to about 60 μm. Advantageously, gloves within these thicknessranges (e.g., about 50 μm) provide strength characteristics in excess ofgloves of comparable thickness prepared from other materials (e.g.,HDPE).

IV. Color Gloves

Various embodiments of the present invention incorporate a coloringagent. Thus, various embodiments are directed to disposable glovesconstructed of ethylene-based polymers that include a coloring agent.The coloring agent can be selected and utilized to indicate the right-or left-handedness of the glove, the size of the glove, or the presenceof one or more additives. For example, the coloring agent may indicatethe presence of an additive selected from the group consisting of a skinprotectant, an anti-bacterial agent, a scent, a degradability enhancingadditive, and combinations thereof.

Generally, the coloring agent is incorporated into one of the filmscomprising the glove construction material. That is, the coloring agentis incorporated into the film used to prepare the surface of the glovethat contacts the palm of the wearer's hand or the film used to preparethe surface that contacts the back surface of the wearer's hand. FIG. 4depicts a glove 1A including a first film 3A and a second film 5A, witha coloring agent 6A incorporated into the material of second film 5A.The coloring agent can be incorporated into either an inner or outerlayer of a multilayer film, or an optional middle layer. The selectionof the layer into which the coloring agent is incorporated is notnarrowly critical.

Multilayer films for use in preparing color gloves of the presentinvention are generally prepared by the coextrusion methods detailedherein. However, since the coloring agent is typically only incorporatedinto one of the films of the glove construction material, color glovesof the present invention are typically prepared from two separate sheetsof multilayer films that are heat-sealed to form the gloves.

Suitable coloring agents include those generally known in the artsuitable for use with polymer-based materials including, for example,low density polyethylene (LDPE), pigments, and color-imparting additivesincluding, for example, coloring agents commercially available fromPolyOne, AmTopp, and NPC. The coloring agent is typically incorporatedin a concentration such that the coloring agent constitutes at leastabout 0.1 wt. %, at least about 3 wt. %, from about 0.1 wt. % to about10 wt. %, or from about 3 wt. % to about 10 wt. % of the film.Additionally or alternatively, the coloring agent typically constitutesat least about 0.1 wt. %, at least about 3 wt. %, from about 0.1 wt. %to about 10 wt. %, or from about 3 wt. % to about 10 wt. % of the layerinto which it is incorporated.

As noted, the coloring agent can indicate the size of the glove or theright- or left-handedness of the glove. The coloring agent can alsoindicate the presence of an additive, including an additive selectedfrom the group consisting of a skin protectant, an anti-bacterial agent,a degradability enhancing additive, and combinations thereof.

In one preferred embodiment of the invention, the glove is made from afirst film and a second film which are heat sealed together as describedabove, and a coloring agent is incorporated into just one of the twofilms. In the final glove, therefore, the palm side of the glove has acoloring agent and the backhand side of the glove does not have acoloring agent; or the palm side of the glove has a coloring agent andthe backhand side of the glove does not have a coloring agent. In theseembodiments as well as in the following embodiments, the coloring agentimparts a color to the glove which is blue, aqua, pink, rose, red,yellow, green, or gold. In other embodiments, other colors are used. Inan alternative embodiment, there is a coloring agent in both sides suchas a first coloring agent in the palm side of the glove and a secondcoloring agent in the backhand side of the glove, wherein the secondcoloring agent is different from the first coloring agent. So in thisembodiment, one side of the glove is a first color and the other side ofthe glove is a second. As is evident from the foregoing, in all of theseembodiments the gloves are essentially flat and are made from two flatfilms heat-sealed together where the two films have a color contrastbetween them, be it either color versus no color, or one color versusanother color. This contrast is important in that it provides thecontrast depicted, for example, between 3 A and 5 A in FIG. 4. Thiscontrast, when the glove is closed and flat, assists the user in openingthe glove for use. In particular, to open a flat glove can often requirepeeling apart the two films, and having the films be contrasting incolor makes it easier for the user to peel the one film off the other,and into an open position.

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the invention pertains. Although a number of methodsand materials similar or equivalent to those described herein can beused in the practice of the present invention, the preferred materialsand methods are described herein.

Having described the invention in detail, it will be apparent thatmodifications and variations are possible without departing from thescope of the invention defined in the appended claims.

EXAMPLES

The following non-limiting examples are provided to further illustratethe present invention.

Each example was below was prepared according to the above-describedprocess and pressed into a disposable glove.

Example 1

Two multilayer films of thermoplastic elastomers according to thepresent invention were prepared including inner, middle, and outerlayers comprising the following components and concentrations in wt. %:

(Inner Layers)

30-50 wt. % metallocene-linear low density polyethylene (m-LLDPE,VERSIFY 3401 available from The Dow Chemical Company);

30-50 wt. % metallocene-linear low density polyethylene (m-LLDPE,AFFINITY PL 1880G available from The Dow Chemical Company);

5-10 wt. % slip additive (oleamide); and

5-10 wt. % antiblock additive (synthetic silica)

(Middle Layer)

100 wt. % LLDPE (L42009 available from Formosa Plastics Corp.

(Outer Layers)

40-60 wt. % metallocene-linear low density polyethylene (m-LLDPE,VERSIFY 3401 available from The Dow Chemical Company);

40-60 wt. % metallocene-linear low density polyethylene (m-LLDPE,AFFINITY PL 1880G available from The Dow Chemical Company);

1-10 wt. % slip additive (oleamide); and

1-10 wt. % antiblock additive (synthetic silica)

For each of the multilayer films, the above-described components wereblended to form the inner, middle, and outer layers and the layers wereco-extruded using separate extruders to form a multilayer thin film thatwas folded, heat sealed, and cut into a disposable glove. The disposableglove prepared from the above-described combination was subjected tovarious standard tests and compared to (1) a commercially availableglove (“PE glove” in the Tables) made from a combination of linear lowdensity polyethylene and high density polyethylene and a (2)commercially available vinyl glove. The results of those tests are shownbelow in Tables 1A (International System Units) and 1B (USCustomary/Imperial Units).

TABLE 1A International System Units Composition Example 1 Combination PEVinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated) μm55.82 10.00 50.00 Density g/cm³ 0.921 0.945 1.25 Tensile Strength MPa6.1 23.7 6.7 ASTM D882 at Yield (MD) Tensile Strength MPa 5.8 N/A 5.3ASTM D882 at Yield (TD) Tensile Strength MPa 20.0 40.4 12.4 ASTM D882 atbreak (MD) Tensile Strength MPa 17.3 25.2 9.7 ASTM D882 at break (TD)Tensile Elongation % 770 290 600 ASTM D882 at Break (MD) TensileElongation % 840 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/μm 5.68 0.23 12.6 ASTM D1922 Tear Strength (TD) grams/μm 10.6510.6 13.6 ASTM D1922 Dart Impact grams/μm 9.9 <1.0 NA ASTM D1709 COF O/O(Static) NA 0.152 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.182 <0.1<0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

TABLE 1B U.S. Customary/Imperial Units Composition Example 1 CombinationPE Vinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated)mil 2.2 0.40 2 Density oz/in³ 0.5251 0.5462 0.723 Tensile Strength psi784 3429 969 ASTM D882 at Yield (MD) Tensile Strength psi 1089 N/A 763ASTM D882 at Yield (TD) Tensile Strength psi 2897 5860 1800 ASTM D882 atbreak (MD) Tensile Strength psi 2501 3650 1400 ASTM D882 at break (TD)Tensile Elongation % 770 290 600 ASTM D882 at Break (MD) TensileElongation % 840 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/mil 144 5.8 160 ASTM D1922 Tear Strength (TD) grams/mil 270 265.3172 ASTM D1922 Dart Impact grams/mil 251 <250 NA ASTM D1709 COF O/O(Static) NA 0.152 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.182 <0.1<0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

Example 2

Two multilayer films of thermoplastic elastomers according to thepresent invention were prepared including inner, middle, and outerlayers comprising the following components and concentrations in wt. %:

(Inner Layers)

-   -   30-50 wt. % metallocene-linear low density polyethylene        (m-LLDPE, VERSIFY 3401 available from The Dow Chemical Company);    -   30-50 wt. % metallocene-linear low density polyethylene        (m-LLDPE, AFFINITY PL 1880G available from The Dow Chemical        Company);    -   5-10 wt. % slip additive (oleamide); and    -   5-10 wt. % antiblock additive (synthetic silica)

(Middle Layer)

-   -   100 wt. % LLDPE (L42009 available from Formosa Plastics Corp.

(Outer Layers)

-   -   40-60 wt. % metallocene-linear low density polyethylene        (m-LLDPE, VERSIFY 3401 available from The Dow Chemical Company);    -   40-60 wt. % metallocene-linear low density polyethylene        (m-LLDPE, AFFINITY PL 1880G available from The Dow Chemical        Company);    -   1-5 wt. % slip additive (oleamide); and    -   1-5 wt. % antiblock additive (synthetic silica)

For each of the multilayer films, the above-described components wereblended to form the inner, middle, and outer layers and the layers wereco-extruded using separate extruders to form a multilayer thin film thatwas folded, heat sealed, and cut into a disposable glove. The disposableglove prepared from the above-described combination was subjected tovarious standard tests and compared to the above-mentioned commerciallyavailable glove made from a combination of linear low densitypolyethylene and high density polyethylene and the above-mentionedcommercially-available vinyl glove. The results of those tests are shownbelow in Tables 2A (International System Units) and 2B (USCustomary/Imperial Units).

TABLE 2A International System Units Composition Example 2 Combination PEVinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated) μm57.08 10.00 50.00 Density g/cm³ 0.921 0.945 1.25 Tensile Strength MPa6.1 23.7 6.7 ASTM D882 at Yield (MD) Tensile Strength MPa 5.8 N/A 5.3ASTM D882 at Yield (TD) Tensile Strength MPa 21.2 40.4 12.4 ASTM D882 atbreak (MD) Tensile Strength MPa 15.9 25.2 9.7 ASTM D882 at break (TD)Tensile Elongation % 849 290 600 ASTM D882 at Break (MD) TensileElongation % 781 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/μm 2.2 0.23 12.6 ASTM D1922 Tear Strength (TD) grams/μm 14.2 10.613.6 ASTM D1922 Dart Impact grams/μm 18.2 <10 NA ASTM D1709 COF O/O(Static) NA 0.331 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.188 <0.1<0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

TABLE 2B U.S. Customary/Imperial Units Composition Example 2 CombinationPE Vinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated)mil 1.1 0.40 2 Density oz/in³ 0.5324 0.5462 0.723 Tensile Strength psi880 3429 969 ASTM D882 at Yield (MD) Tensile Strength psi 841 N/A 763ASTM D882 at Yield (TD) Tensile Strength psi 3068 5860 1800 ASTM D882 atbreak (MD) Tensile Strength psi 2313 3650 1400 ASTM D882 at break (TD)Tensile Elongation % 849 290 600 ASTM D882 at Break (MD) TensileElongation % 781 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/mil 56 5.8 160 ASTM D1922 Tear Strength (TD) grams/mil 358.5 265.3172 ASTM D1922 Dart Impact grams/mil 460 <250 NA ASTM D1709 COF O/O(Static) NA 0.331 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.188 <0.1<0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

Example 3

Two multilayer films of thermoplastic elastomers according to thepresent invention were prepared including inner, middle and outer layerscomprising the following components and concentrations in wt. %:

(Inner Layers)

-   -   30-50 wt. % metallocene-linear low density polyethylene        (m-LLDPE, VERSIFY 3401 available from The Dow Chemical Company);    -   30-50 wt. % metallocene-linear low density polyethylene        (m-LLDPE, AFFINITY PL 1880G available from The Dow Chemical        Company);    -   5-10 wt. % slip additive (oleamide); and    -   5-10 wt. % antiblock additive (synthetic silica)

(Middle Layer)

-   -   100 wt. % LLDPE (L42009 available from Formosa Plastics Corp.

(Outer Layers)

-   -   40-60 wt. % metallocene-linear low density polyethylene        (m-LLDPE, VERSIFY 3401 available from The Dow Chemical Company);    -   40-60 wt. % metallocene-linear low density polyethylene        (m-LLDPE, AFFINITY PL 1880G available from The Dow Chemical        Company);    -   1-5 wt. % slip additive (oleamide); and    -   1-5 wt. % antiblock additive (synthetic silica)

For each of the multilayer films, the above-described components wereblended to form the inner, middle, and outer layers and the layers wereco-extruded using separate extruders to form a multilayer thin film thatwas folded, heat sealed, and cut into a disposable glove. The disposableglove prepared from the above-described combination was subjected tovarious standard tests and compared to the above-notedcommercially-available glove made from a combination of linear lowdensity polyethylene and high density polyethylene and the above-notedcommercially available vinyl glove. The results of those tests are shownbelow in Tables 3A (International System Units) and 3B (USCustomary/Imperial Units).

TABLE 3A International System Units Composition Example 3 Combination PEVinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated) μm51.0 10.00 50.00 Density g/cm³ 0.891 0.945 1.25 Tensile Strength MPa 4.823.7 6.7 ASTM D882 at Yield (MD) Tensile Strength MPa 4.3 N/A 5.3 ASTMD882 at Yield (TD) Tensile Strength MPa 15.6 40.4 12.4 ASTM D882 atBreak (MD) Tensile Strength MPa 16.1 25.2 9.7 ASTM D882 at Break (TD)Tensile Elongation % 716 290 600 ASTM D882 at Break (MD) TensileElongation % 816 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/μm 5.1 0.23 12.6 ASTM D1922 Tear Strength (TD) grams/μm 9.9 10.613.6 ASTM D1922 Dart Impact grams/μm 12.5 <10 NA ASTM D1709 COF O/O(Static) NA 0.759 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.172 <0.1<0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

TABLE 3B U.S. Customary/Imperial Units Composition Example 3 CombinationPE Vinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated)mil 2.0 0.40 2 Density oz/in³ 0.5150 0.5462 0.723 Tensile Strength psi689 3429 969 ASTM D882 at Yield (MD) Tensile Strength psi 617 N/A 763ASTM D882 at Yield (TD) Tensile Strength psi 2254 5860 1800 ASTM D882 atBreak (MD) Tensile Strength psi 2338 3650 1400 ASTM D882 at Break (TD)Tensile Elongation % 716 290 600 ASTM D882 at Break (MD) TensileElongation % 816 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/mil 131.6 5.8 160 ASTM D1922 Tear Strength (TD) grams/mil 253.2265.3 172 ASTM D1922 Dart Impact grams/mil 319 <250 NA ASTM D1709 COFO/O (Static) NA 0.759 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.172<0.1 <0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

Example 4

Two multilayer films of thermoplastic elastomers according to thepresent invention were prepared including inner, middle, and outerlayers comprising the following components and concentrations in wt. %:

(Inner Layers)

-   -   30-50 wt. % metallocene-linear low density polyethylene        (m-LLDPE, VERSIFY 3401 available from The Dow Chemical Company);    -   30-50 wt. % metallocene-linear low density polyethylene        (m-LLDPE, AFFINITY PL 1880G available from The Dow Chemical        Company);    -   5-10 wt. % slip additive (oleamide); and    -   5-10 wt. % antiblock additive (synthetic silica)

(Outer/Middle)

-   -   48 wt. % AFFINITY PL 1880G available from The Dow Chemical        Company);    -   48 wt. % metallocene-linear low density polyethylene (m-LLDPE,        VERSIFY™ 3401 available from The Dow Chemical Company);    -   0-5 wt. % slip additive (oleamide); and    -   0-5 wt. % antiblock additive (synthetic silica or Talc)

For each of the multilayer films, the above-described components wereblended to form the inner, middle, and outer layers and the layers wereco-extruded using separate extruders to form a multilayer thin film thatwas folded, heat sealed, and cut into a disposable glove. The disposableglove prepared from the above-described combination was subjected tovarious standard tests and compared to the above-noted commerciallyavailable glove made from a combination of linear low densitypolyethylene and high density polyethylene and the above-notedcommercially available vinyl glove. The results of those tests are shownbelow in Tables 4A (International System Units) and 4B (USCustomary/Imperial Units).

TABLE 4A International System Units Composition Example 4 Combination PEVinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated) μm60.6 10.00 50.00 Density g/cm³ 0.905 0.945 1.25 Tensile Strength MPa 3.623.7 6.7 ASTM D882 at Yield (MD) Tensile Strength MPa 3.5 N/A 5.3 ASTMD882 at Yield (TD) Tensile Strength MPa 20.9 40.4 12.4 ASTM D882 atBreak (MD) Tensile Strength MPa 17.8 25.2 9.7 ASTM D882 at Break (TD)Tensile Elongation % 832 290 600 ASTM D882 at Break (MD) TensileElongation % 849 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/μm 4.62 0.23 12.6 ASTM D1922 Tear Strength (TD) grams/μm 8.34 10.613.6 ASTM D1922 Dart Impact grams/μm >14.4 <10 NA ASTM D1709 COF O/O(Static) NA 1.275 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.185 <0.1<0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

TABLE 4A U.S. Customary/Imperial Units Composition Example 4 CombinationPE Vinyl Test Item Unit Value glove Glove Test Method Gauge (Calculated)mil 2.38 0.40 2 Density oz/in³ 0.5231 0.5462 0.723 Tensile Strength psi520 3429 969 ASTM D882 at Yield (MD) Tensile Strength psi 507 N/A 763ASTM D882 at Yield (TD) Tensile Strength psi 3029 5860 1800 ASTM D882 atBreak (MD) Tensile Strength psi 2582 3650 1400 ASTM D882 at Break (TD)Tensile Elongation % 832 290 600 ASTM D882 at Break (MD) TensileElongation % 849 590 295 ASTM D882 at Break (TD) Tear Strength (MD)grams/mil 117.6 5.8 160 ASTM D1922 Tear Strength (TD) grams/mil 212.5265.3 172 ASTM D1922 Dart Impact grams/mil >367 <250 NA ASTM D1709 COFO/O (Static) NA 1.275 <0.1 <0.1 ASTM D1894 COF I/I (Static) NA 0.185<0.1 <0.1 ASTM D1894 Seal Temperature ° C. 80-90 125-130 NA

When introducing elements of the present invention or the preferredembodiments(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

In view of the above, it will be seen that the several objects of theinvention are achieved and other advantageous results attained.

As various changes could be made in the above products and methodswithout departing from the scope of the invention, it is intended thatall matter contained in the above description shall be interpreted asillustrative and not in a limiting sense.

It should be understood that the present invention is not limited to anyparticular construction or technique for making the glove althoughvarious structures and techniques for forming thermoplastic materialshave been described above. For example, the layers described above maynot be utilized in all occasions. Additionally, other layers notspecifically referred to above may be utilized in the present invention.

What is claimed is:
 1. A disposable glove comprising: a gloveconstruction material adapted for receiving a thumb, fingers, and/or ahand therein, and comprising a plurality of ethylene-based polymerlayers, the glove construction material comprising: (a) a first filmhaving a thickness of from about 5 to about 40 μm and comprising: (i) afirst inner layer comprising (I) a first metallocene-linear low densitypolyethylene (m-LLDPE), and (II) at least one ethylene-based polymerselected from the group consisting of a second metallocene-linear lowdensity polyethylene (m-LLDPE), an ethylene-vinyl acetate copolymer(EVA), a linear low density polyethylene (LLDPE), and combinationsthereof, the first inner layer comprising at least about 60 wt. %m-LLDPE; and (ii) a first outer layer comprising (I) a firstmetallocene-linear low density polyethylene (m-LLDPE), and (II) at leastone ethylene-based polymer selected from the group consisting of asecond metallocene-linear low density polyethylene (m-LLDPE), anethylene-vinyl acetate copolymer (EVA), a linear low densitypolyethylene (LLDPE), and combinations thereof; the first outer layercomprising at least about 80 wt. % m-LLDPE; and (iia) a first middlelayer disposed between and in contact with the unexposed surface of thefirst inner layer and the unexposed surface of the first outer layer,the first middle layer comprising a linear low density polyethylene(LLDPE) and optional additives selected from one or more fillers and/orone or more mineral additives; and wherein the composition of the firstinner layer, first middle layer, and first outer layer are different;(b) a second film having a thickness of from about 5 to about 40 μm andcomprising: (iii) a second inner layer comprising (I) a firstmetallocene-linear low density polyethylene (m-LLDPE), and (II) at leastone ethylene-based polymer selected from the group consisting of asecond metallocene-linear low density polyethylene (m-LLDPE), anethylene-vinyl acetate copolymer (EVA), a linear low densitypolyethylene (LLDPE), and combinations thereof, the second inner layercomprising at least about 60 wt. % m-LLDPE; and (iv) a second outerlayer comprising (I) a first metallocene-linear low density polyethylene(m-LLDPE), and (II) at least one ethylene-based polymer selected fromthe group consisting of a second metallocene-linear low densitypolyethylene (m-LLDPE), an ethylene-vinyl acetate copolymer (EVA), alinear low density polyethylene (LLDPE), and combinations thereof; thesecond outer layer comprising at least about 80 wt. % m-LLDPE; and (iva)a second middle layer disposed between and in contact with the unexposedsurface of the second inner layer and the unexposed surface of thesecond outer layer, the second middle layer comprising a linear lowdensity polyethylene (LLDPE) and optional additives selected from one ormore fillers and/or one or more mineral additives; wherein thecomposition of the second inner layer, second middle layer, and secondouter layer are different.
 2. The glove of claim 1 wherein the firstmiddle layer and/or second middle layer further comprise ametallocene-linear low density polyethylene (m-LLDPE), an ethylene-vinylacetate copolymer (EVA), a linear low density polyethylene (LLDPE), or acombination thereof.
 3. The glove of claim 1 wherein the first middlelayer and second middle layer each have a thickness of from about 10 μmto about 30 μm.
 4. The glove of claim 1 wherein the first inner layerand second inner layer comprise a first metallocene-linear low densitypolyethylene (m-LLDPE) and a second metallocene-linear low densitypolyethylene (m-LLDPE).
 5. The glove of claim 1 wherein the first innerlayer and second inner layer comprise a first metallocene-linear lowdensity polyethylene (m-LLDPE) and an ethylene-vinyl acetate copolymer(EVA).
 6. The glove of claim 1 wherein the first inner layer and secondinner layer comprise a first metallocene-linear low density polyethylene(m-LLDPE) and a linear low density polyethylene (LLDPE).
 7. The glove ofclaim 1 wherein the first inner layer comprises a surface modificationagent selected from the group of a slip additive, an anti-blockadditive, and mixtures thereof.
 8. The glove of claim 1 wherein theexposed inner surfaces of the first inner layer and second inner layerhave a coefficient of friction (COF) of less than about 0.3 and theexposed outer surfaces of the first outer layer and second outer layerhave a COF of at least about 0.5.
 9. The glove of claim 1 wherein theratio of the coefficient of friction (COF) of the exposed outer surfaceof the first outer layer to the COF of the exposed inner surface of thefirst inner layer is at least 1.5 and the ratio of the COF of theexposed outer surface of the second outer layer to the COF of theexposed inner surface of the second inner layer is at least 1.5.
 10. Theglove of claim 1 wherein the first film is prepared by co-extruding thefirst inner layer, first middle layer and first outer layer and thesecond film is prepared by co-extruding the second inner layer, secondmiddle layer and second outer layer.
 11. The glove of claim 1 having atensile strength at yield (MD) of no more than about 14 MPa.
 12. Theglove of claim 1 having a tensile strength at yield (TD) of no more thanabout 14 MPa.
 13. The glove of claim 1 characterized by dart impact testresults conducted in accordance with ASTM D1709 of at least about 8g/μm.
 14. The glove of claim 1 having: (a) a tensile elongation at break(MD) of at least about 700%; and/or (b) a tensile elongation at break(TD) of at least about 700%; and/or (c) dart impact test resultsconducted in accordance with ASTM D1709 of at least 10 g/μm.
 15. Thedisposable glove of claim 1 wherein the glove construction material hasa thickness of at least 50 μm and a density of less than 0.92 g/cm³. 16.The glove of claim 1 wherein the glove construction material has athickness of from about 40 μm to about 60 μm and being characterized by:(i) a tensile strength at yield (MD) of no more than about 23 MPa;and/or (ii) a tensile strength at yield (TD) of no more than about 10MPa; and/or (iii) a tensile strength at break (MD) of no more than about40 MPa; and/or (iv) a tensile strength at break (TD) of no more thanabout 25 MPa; and/or (v) a tensile elongation at break (MD) of at leastabout 700%; and/or (vi) a tensile elongation at break (TD) of at leastabout 800%; and/or (vii) a tear strength (MD) of at least about 1 g/μm;(viii) a tear strength (TD) of at least about 2 g/μm; and/or (ix) dartimpact test results conducted in accordance with ASTM D1709 of at least10 grams/μm; and/or (x) the coefficient of friction of the exposedsurface of the inner layer of the first film and the exposed surface ofthe inner layer of second film being from about 0.1 to about 0.3; (xi)the coefficient of friction of the exposed outer surface of the outerlayer of the first film and the exposed surface of the outer layer ofthe second film being from about 0.1 to about 0.5.
 17. The glove ofclaim 1 wherein the first inner layer and the first outer layer furthercomprise one or more surface modification agents, the ratio of the totalproportion of the one or more surface modification agents in the firstinner layer to the total proportion of surface modification agents inthe first outer layer is at least 2:1 (wt. %/wt. %); and the secondinner layer and the second outer layer further comprising one or moresurface modification agents, wherein the ratio of the total proportionof surface modification agents in the second outer layer to the totalproportion of surface modification agents in the second inner layer isat least 2:1 (wt. %/wt. %).
 18. The glove of claim 1 wherein the exposedsurfaces of the first inner layer and the second inner layer have acoefficient of friction (COF) of less than about 0.3 and the exposedsurfaces of the first outer layer and the second outer layer have a COFof at least about 0.5.
 19. The glove of claim 1 wherein: the first innerlayer and the first outer layer each comprises one or more surfacemodification agents, the first inner layer including a greaterproportion of surface modification agent(s) than the first outer layer;and the second inner layer and the second outer layer each comprises oneor more surface modification agents, the second inner layer including agreater proportion of surface modification agent(s) than the secondouter layer.
 20. The glove of claim 19 wherein: the first inner layercomprises between about 5 wt. % and about 10 wt. % of a slip additiveand between about 5 wt. % and about 10 wt. % of an anti-block additive,the first outer layer comprising between about 1 and about 5 wt. % of aslip additive and between about 1 and about 5 wt. % of an anti-blockadditive; and the second inner layer comprises between about 5 wt. % andabout 10 wt. % of a slip additive and between about 5 wt. % and about 10wt. % of an anti-block additive, the second outer layer comprisingbetween about 1 and about 5 wt. % of a slip additive and between about 1and about 5 wt. % of an anti-block additive.
 21. The glove of claim 1,wherein the first film comprises a coloring agent which imparts a firstcolor to the first film, and wherein the second film is free of anycoloring agent which would impart the first color so that the secondfilm and the first film have a color contrast; and wherein the firstfilm and second film are each flat films heat-sealed to each other witheither the first or second film being a palm side film of the glove andthe other film being a backhand side film of the glove so said colorcontrast is a color contrast distinguishing the backhand side film ofthe glove from the palm side film.
 22. The glove of claim 21 wherein thecolor contrast between the first and second flat films achieves afunction of assisting the user in opening the glove, and/or the coloringagent achieves a function to indicate the right- or left-handedness ofthe glove, the size of the glove, or the presence of one or moreadditives.